Amphibious structure

ABSTRACT

A pair of shell-like structures, each integrally cast from a polymeric material, form upper and lower members which together define a hollow enclosure or cavity. The lower member is formed of a polymeric material having a higher density than that of the upper member to provide stability and structural strength for the structure.

United States Patent inventor Domenico Mortellito 716 W. Matson Run Parkway, Brandywine Hills, Wilmington, Del. Appl No. 795,607 Filed Jan. 31, 1969 Patented June 1, 1971 AMPHIBIOUS STRUCTURE 10 Claims, 5 Drawing Figs.

US. Cl ll4/0.5 Int. Cl B63!) 35/00 Field of Search 1 14/05, 0.5 F;9/l,6;l6l/160 Primary Examiner-Trygve M. Blix Attorney-Mortenson and Weigel ABSTRACT: A pair of shell-like structures, each integrally cast from a polymeric material, form upper and lower members which together define a hollow enclosure or cavity. The lower member is formed of a polymeric material having a higher density than that of the upper member to provide stability and structural strength for the structure.

PATENIEU Jun 1 I97! SHEU 1 OF 3 a. m mm m YZW ll :5 I. f 2

PATEMNTEDJUN H91! 3581; 692

SHEET 2 [IF 3 Q I "V E N TOR Domenico Mortellilo MDZ ATTORNEKS PATENTED Jun 1 I97! 7 SHEET 3 OF 3 INVENTOB V DomanicoMorLellilo BY W40 AMPIIIBIOUS s'mlucrunls BACKGROUND OF THE INVENTION Conventional houses and other living structures typically are built either on site or at a factory by assembling literally thousands of individual components, each of which must be individually sized, cut and fitted together to form the house. The labor required to thus complete the house is relatively costly. In addition, presently available materials such as wood, metal, and the like used in building the house are relatively expensive in themselves. They must each be prepared or processed from raw materials thereby adding another increment of cost. Aside from the cost, the houses thus formed often have insulation problems and attendant heating or cooling problems. Additional limitations imposed by use of these many components include that of design. Houses typically are built in standard shapes having corners, which are little more than dust collectors, and planar walls, floors, and ceilings having little aesthetic appeal. Furthermore, because of settling and the fact that the various materials used in a home often have different coefficients of expansion with temperature, there is a tendency for cracks to develop in the walls ceilings and floors.

Aside from these many disadvantages found in existing homes, there is another factor to be considered for the future- -the availability of space problem. With the population of the world increasing at an ever faster rate, the existing land areas suitable for home building are rapidly disappearing. When this consideration is coupled with the fact that over half, i.e., approximately five-sevenths to five'eights, of the earth's surface is water, it becomes desirable to provide homes and other shelters that are equally adaptable for use on land as well as water. Existing homes built on water must be either built on stilts, which places a severe limitation on the areas in which they can actually be built, or on a boat hull. Such homes on stilts are restricted generally to regions contiguous to the shore where the water is relatively shallow.

Homes built on a boat-hull, the existing so-called houseboats, are presently available and are used in water. Such houseboats, however, require the conventional hull of a boat or barge for flotation. This renders them not only expensive but also tends to limit the practical living area for the family and requires yearly maintenance, repainting, etc. They are relatively difficult to move and are generally limited to use in locations to which access may be had through seaways. They find litt e use on inland lakes, for example.

It is, therefore, an object of this invention to provide an improved amphibious structure.

Another object of this invention is to provide an improved amphibious structure which is relatively low cost and simple to construct.

BRIEF DESCRIPTION OF THE INVENTION In a preferred embodiment, the amphibious structure of this invention comprises mating base and closure members each integrally formed of a polymeric material. The m3mbers are generally shell-like and are secured together to define a living cavity for people. Preferably, the base member is formed of a polymeric material having a higher density than that of the closure member to provide the desired structural strength and to improve its flotation characteristics. Conduits for fluids and electricity are cast directly within the respective mating mem bers. Furniture and partitions for the living cavity also are formed and fitted together simultaneously with the mating base enclosure members so as to be integral therewith.

BRIEF DESCRIPTION OF THE DRAWINGS The novel features that are considered characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, as well as additional objects and advantages thereof, will be best understood from the following description when read in connection with the accompanying drawings in which:

FIG. 1 is a front elevation view of the amphibious structure of this invention depicted in a water environment;

FIG. 2 is a side elevation view of the structure illustrated in FIG. 1 taken in cross section along the section line 2-2;

FIG. 3 is a plan view of the base member forming the structure illustrated in FIG. 1;

FIG. 4 is a plan view of the upper or closure member forming the structure illustrated in FIG. 1; and

FIG. 5 is an enlarged partial cross-sectional view of the structure illustrated in FIG. 1 showing the manner in which the upper and lower closure members fit together.

DESCRIPTION OF THE PREFERRED EMBODIMENT There is seen in FIG. 1 an amphibious structure 10, constructed in accordance with this invention, floating on a water environment 12. The structure 10 is formed from two mating upper and lower shell-like members which are designated, respectively, a closure member 16 and a base member 14. The manner in which the members 14 and 16 fit together to form what may be described as a partially hollow enclosure or cavity 18 may be seen, perhaps most clearly, in the cross-sectional views of FIGS. 2 and 5. As seen in these figures, the peripheral, contacting edges 20 and 21 of the mating members 14, 16, respectively, are formed to define a lap joint 19. This lap joint (other known joints or flush contacting edges 20, 21 may be used) is preferred since it is water resistant and sheds water from the structure even when the joint is left unsealed. Preferably, however, the joint is sealed as will be described.

In accordance with this invention each of the members 14 and 16 are formed from a synthetic polymeric material. In the past 10 years or so synthetic polymers have been steadily increasing in tonnages used annually and more and more of such materials are being used in the construction fields. Such polymers include the polyphenyl polymers, polyamides, polyolefins, polyesters, and the polyurethanes. While these are useful in various forms in the present invention, the polyurethanes are preferred for the purposes of this invention. These are available commercially for use in nonporous forms and for use as foams. Further, they can be preferred in a custom-built manner so that one could virtually construct a given element or portion of the structure to have properties desired. For example, the polyurethanes are available for the formation of flexible, semirigid or rigid foams. The densities can be from substantially less than 1 pound per cubic foot to 30 pounds per cubic foot or even higher. The shaped articles made from polyurethanes can have high impact strengths, tough resilient or tough nonresilient exteriors and a great variety of finishes. Finally, with the immense amounts of polyurethanes being annually consumed on an increasing basis, the polyurethanes have become attractively priced.

Basically, there are two methods of forming polyurethane foams. One is the one-shot method and the other is the prepolymer technique. In the one-shot procedure a polyisocyanate, such as toluene diisocyanate, and a dior polyfunctional active hydrogen-containing substance are reacted in the presence of a catalyst promoting the reaction and in the presence of a surfactant and water and/or a blowing agent. Mixing generally occurs in the mixing head of certain apparatus which then effects the pumping of the mixture into cavities of a subject mold. Foaming then occurs either due to the liberation of carbon dioxide from the reaction with water of unchanged isocyanato groups purposely present for that reaction or foaming occurs by the polymerization of a contained blowing agent such as monofluorotrichloromethane. Frothing techniques can also be used.

Inthe prepolymer technique, the polyisocyanate is reacted with an amount of another, different dior polyfunctional material to produce a polymer that is a polyurethane and that is still reactive. This component is usually referred to as the A" component. It is capable of reacting with additional amounts of the dior polyfunctional material which is usually referred to as the B component at this stage. Generally, the dior polyfunctional material is itself a polymer and preferably this is a polyether/polyol prepared by reacting alkylene oxides, such as ethylene oxide or propylene oxide or mixtures thereof with any of a wide variety of polyols. Of these, there may be mentioned glycols such as ethylene glycol, propylene glycol, polyethylene glycol, polypropylene glycol and higher hydroxylated materials such as glycerol, 1,2,6-hexane triol, trimethylol propane, pentaerythritol, sorbitol, sucrose, fructose, mannose, adonitol, and glycocides, among many others including mixtures of these as well as the polyamines and amino alcohols.

One need only contact anyone of the many producers of polyurethanes or components therefor to obtain not only all the supply he needs but adequate brochures and the like relating to the handling of the polyurethanes and for their conversion to foams or nonporous shaped articles. While the polyurethanes that an be used in this invention include the polyesters-that is, those obtained by reacting diisocyanates with a polyester such as ethylene glycol-edapic acid polyester, the polyether types described above are preferred because they give the properties desired, are easier to handle and are cheaper.

Further, the polyether polymers are available in a large variety of molecular weights and the production of final products having desired properties is made easy through their use. Thus, one can be filling one cavity of an open mold with a polyurethane of one kind to give a shaped element in the structure having a low density while at the same time another cavity is being filled with a polyurethane to form a different element having a substantially different density. Such cavities may be filled with foamable or nonfoamable material as desired. The reactions involved in the foaming are exothermic but are very controllable. If water is the blowing agent, the amount needed to produce the desired extent of foaming is precalculated and is present in the 8" component. Generally, blowing is effected in the absence of water by using such blowing agents as the fluorocarbons of which dichlorodifluoromethane and dichlorofluoromethane may also be needed. The amount of blowing agent will, of course, vary with the density desired for the given element, and, as stated, the producers of polyurethane have such factors taken care of in their commercial products.

Thus, one may build a wall having excellent insulation properties by virtue of its being made from a fluorocarbon-blown polyurethane which has many closed cells with fluorocarbon trapped therein, and he may, at the same time, using the same mold, build a ceiling which is integral with that wall but which is made up of a much lower density polyurethane. Similarly, structural elements such as braces or supports such as seats can be shaped in the open mold producing the structures of this invention in concurrent operations.

Rigid polyurethane foams are preferred because they have many highly desirable characteristics. Among these desirable characteristics are their resistance to temperature effects, their relatively high strength and, in the lower densities, their relative light weight. Furthermore, rigid urethane foam has good acoustical properties. lt has no grain and is translucent in thin sections. It will adhere to most surfaces and can receive coatings of paint, metals, or other known coating materials.

Many of these properties of urethane foam are utilized in the structure 10. The base and closure members 14 and 16, respectively, are each integrally formed as by molding. Alternatively, and depending upon the design structure desired, the members 14 and 16 may be formed by known extrusion processes to be either integral or laminated sheets. Let us consider first the construction of the base member 14. The base member 14 is constructed or formed by first completing conduit or wire trees having all the desired electrical conduits or wiring 60 as may be necessary for the completed house or other living structure that is to be formed. These electrical conduit trees 60 may be formed in much the same manner as is presently employed in electronic instrumentation, i.e., the several conduits or wire are laid out according to a predetermined wirir.g design or tree" that will fit into or fall within the walls and partitions of the base member 14. Stated in another manner, the conduits are shaped during this phase of the construction of the enclosure so as to be molded within the base, wall, or partition portions of the completed structure.

Next, the necessary conduits or pipes for carrying fluids, i.e., water, sewerage, etc. are similarly assembled in trees" 62 so as to fall within the base and wall or partitions of the completed structure. Preferably, for this purpose, plastic piping of known type may be employed. The electrical conduit trees 60 and the pipes or pipe trees 62 are extended to the upper peripheral edge 20 of the base member 14. At this point, appropriate snap or pluggable connectors 63 are employed to permit connections with similar electric conduits 60 or pipes 62 included within the upper closure member 16 where necessary. Snap fittings of this type for plastic piping have been available for a number of years. in like manner, (pluggable) connectors for electrical connections are also available commercially if wires are employed instead of conduits.

The completed electrical conduit trees 60 and fluid conduits or pipe trees 62 are positioned within the mold. The desired polymeric material is then injected into the mold in accordance with known techniques. As soon as the polymeric material has hardened or set up," the mold is removed and the base member 14 is complete. The upper or closure member 16 is formed in like manner, with the interconnecting pipes and conduits in alignment such that proper connections can be made when the two members l4, 16 are placed together.

Preferably the base member 14 is formed, as may be seen most clearly in FIG. 2, to have a lower hollow protuberance 22. This lower protuberance is adapted to house a furnace or other suitable power plant for heating or cooling the amphibious structure. It may be, of course, provided with a chimney (not shown) which desirably extends upwardly through the central portion of the structure 10. For aesthetic purposes the structure 10 is formed to have front opening or orifice to permit ingress and egress to the interior of the house. The opening is defined by cooperating U-shaped portions in the peripheral edges 14, 16. Also for aesthetic purposes the members 14, 16 are molded to have protruding shaped lip portions 24. A similar orifice 26 is formed in the mating base and closure members 14 and 16 to provide a front orifice 26. If desired, other accessories to the house such as a boat dock 28 may be included in the structure of the base member 14.

Both the base and closure members 14 and 16, respectively, are formed to have sheetlike mating protuberances 30 which provide the walls or partitions within the completed structure. These, of course, may be laid out according to any desired design. As previously mentioned, the upper and lower mating peripheral edges 20 and 21 of the members 14 and 16 are formed to provide an exterior overhang or lap joint to aid in repelling rain and other fluids. This also aids in securing the members 14 and 15 together. When they are completed, base and enclosure members 14 and 16, respectively, are merely placed together such that their peripheral edges 20 and 21 are in contact and interlock. Preferably, a sealant 64 of the same polymeric material as the members is introduced into this joint to provide a seal. An advantage of using the same polymeric material is that the seal, being of the same material as the molded members 14 and 16, adheres quite well.

The floor areas wherein people are likely or intended to walk on the base member 14 may be formed, during the molding process, of a more dense material by injecting polymeric material of a more dense constituency into these regions during the molding process. A like statement may be made with respect to the exterior of the structure 10, particularly as to those portions which are subject to friction or bumping from adjacent structures or to wear as by the boat docking. Alternatively, these portions which are subject to stresses of this type may be formed of a laminate material. This laminate may be formed either by using a conventional fiberglass laminate, which is well known and which may be adhered to the exterior of the structure and to other surfaces where necessary. Alternatively, the laminate may be formed of the same polymeric material of which the structure itself is formed, the alternate plies being formed of rigid sheets of a suitable rigid material. Suitable rigid materials would include sheets of metal, wood or even other plastics. Laminates of this type are particularly suitable for kitchen and bathroom surfaces as well as forming doors, which may be separately formed. Such laminates may be part of the molding process or may be applied after the 1 structure is formed using commercially available adhesives.

Further in accordance with the preferred embodiment of this invention, during the formation of the base and closure members 14 and 16, respectively, the mold may be designed to form fumittre 34 integrally within the structure 10. Those portions of the structure wherein a greater structural strength is required, may be formed during the molding process with a denser material. Such portions may be in the shape of ribs or beams 36 of this denser, stronger, polymeric material. One such region 36 may provide the structural reinforcement necessary to permit the placement of a lifting hook 38 having support arms molded in reinforced regions 36 in the top of the structure 10. Thisfacilitates the lifting and transport of the structure as by helicopter or other lifting device to different locations on either the water or on land.

In a typical example, where greater structural strength is desired, portions of the base member 14 may be formed of foam having a density of 12 pounds per cubic foot, whereas the closure member 16 and partitions within the structure may be formed of material having a 6 pound per cubic foot density. Additionally; sections 40 may be fonned in the closure member 16 of reduced wall thickness to permit a soft filtration of light into the interior of the structure. Sections of this type may be formed of even lighter density foam say in the order of 4 pounds per cubic foot and less.

As a typical example, to provide a housing structure of this type, the interior of the structure 10 might be formed, as seen in FIG. 3, to have a stepdown living area 42 with a conversation well, a dining area 44, a kitchen 46, an auxiliary room 48, bedrooms 50, and a bathroom 52, all of these being separated by the mating protuberances or walls 30 molded integrally with the respective members 14 and 16. The jointure of these mating protuberances may be either at the floor or at any point along the wall. A sealant of the same polymeric material as the members may be used to join the two. Doors, either of the laminated variety or conventional, may be installed in the entrances to the several rooms as desired. The ceiling of the rooms preferably is dome-shaped to provide a stronger structure by reinforcing the jointure of the walls and ceiling with additional foam material.

The structure thus formed has many advantages in addition to ease and economy of construction. The structure is mobile and a good insulator because of the nature of the plastic material of which it is formed. Preferably fireproof polymeric materials are used. Since the entire structure is fonned of the same material, having substantially the same temperature coefficient of expansion, cracks are less likely to form than in conventional houses. The structure may be used with equal facility on land or water. Any repairs that need be done are Simply accomplished merely by removing the material to obtajn access to the area in which the repair is required. After the repair is completed, a replacement foam may be sprayed into place and smoothed off.

When completed, for effect and added protection from the elements, the exterior of the surfaces, both inside and out, may be painted in a conventional manner. Alternatively, they may be sprayed with a finish of metal, resin, epoxy, elastomeric resin, lacquer, fluorocarbon resins or other suitable finishes. By use of polymeric materials, particularly polyurethane foam, there is little problem with typical homeowner problems of mildew, rot, etc. Furthermore, plastics of this type may be termed antivermin inasmuch as vermin have little disposition to eat into materials of this type.

It is obvious that many embodiments may be made of this inventive concept and that many modifications may be made in the embodiments hereinbefore described. Therefore, it is to be understood that all descriptive matter herein is to be interpreted merely as illustrative, exemplary, and not in a limited sense. It is intended that various modifications which might readily suggest themselves to those skilled in the art be covered by the following claims, as far as the prior art permits.

What I claim is: I. An amphibious structure comprising: mating base and closure members, each integrally formed by casting a polymeric material such as polyurethane and defining a space for habitation between said members,

said members being sealed together with said polymeric material, whereby the coefficient of expansion of substantially all portions of said structure is substantially the same, thereby to reduce structural faults caused by temperature changes, and at least some portions of the polymeric material of said base member having a higher density than that of said closure member to provide greater structural strength and to enhance the upright stability of said structure when in the water or on land. 2. An amphibious structure according to claim 1 which also includes:

furniture integrally cast with said base member, and

wherein said members each have an opposed mating,

partitionlike protuberance integrally cast therewith thereby to define at least partially partitioned regions within said cavity.

3. An amphibious structure according to claim 1 wherein:

said members each have an opposed mating, partitionlike protuberance integrally cast therewith thereby to define at least partially partitioned regions within said cavity, and

wherein a portion of said base member adjacent said cavity forms a walking surface, said portion being a layer of said polymeric material integral with said base member and having a density higher when that of the remainder of said base member thereby to provide said walking surface.

4. An amphibious structure according to claim 1 which also includes furniture integrally formed with said base member.

5. An amphibious structure according to claim 1 wherein said members each have opposed mating, partitionlike protuberances integrally formed therewith, thereby to define at least partially partitioned regions within said cavity.

6. An amphibious structure according to claim 1 wherein portions of said base member defining said cavity are laminates formed of layers of said polymeric material and sheets of a rigid material, said'laminates being substantially integral with said base member.

7. An amphibious structure according to claim 1 wherein a portion of said base member adjacent said cavity forms a walking surface, said portion being a layer of said polymeric material integral with said base member and having a density higher than that of the remainder of said base member thereby to provide said walking surface.

8. An amphibious structure according to claim 1 wherein each of said members have discrete integral regions of higher density than that of the remainder of said members, respectively, thereby to form structural supports of higher strength.

9. An amphibious structure according to claim 8 wherein said closure portion has a wall portion of reduced thickness, thereby to form a translucent region therein for the admission of light.

10. An amphibious structure comprising:

mating base and closure members, each integrally formed of a polymeric material such as polyurethane,

said members being secured together to define a cavity,

the polymeric material of said base member having a higher density than that of said closure member,

said members being sealed together with said polymeric material, whereby the coefficient of expansion of substanfor ingress and egress to said cavity, and

a portion of said base member adjacent said cavity having a walking surface, said portion being a layer of said polymeric material integral with said base member and having a density higher than that of the remainder of said base member, thereby to provide said walking surface. 

1. An amphibious structure comprising: mating base and closure members, each integrally formed by casting a polymeric material such as polyurethane and defining a space for habitation between said members, said members being sealed together with said polymeric material, whereby the coefficient of expansion of substantially all portions of said structure is substantially the same, thereby to reduce structural faults caused by temperature changes, and at least some portions of the polymeric material of said base member having a higher density than that of said closure member to provide greater structural strength and to enhance the upright stability of said structure when in the water or on land.
 2. An amphibious structure according to claim 1 which also includes: furniture integrally cast with said base member, and wherein said members each have an opposed mating, partitionlike protuberance integrally cast therewith thereby to define at least partially partitioned regions within said cavity.
 3. An amphibious structure according to claim 1 wherein: said members each have an opposed mating, partitionlike protuberance integrally cast therewith thereby to define at least partially partitioned regions within said cavity, and wherein a portion of said base member adjacent Said cavity forms a walking surface, said portion being a layer of said polymeric material integral with said base member and having a density higher when that of the remainder of said base member thereby to provide said walking surface.
 4. An amphibious structure according to claim 1 which also includes furniture integrally formed with said base member.
 5. An amphibious structure according to claim 1 wherein said members each have opposed mating, partitionlike protuberances integrally formed therewith, thereby to define at least partially partitioned regions within said cavity.
 6. An amphibious structure according to claim 1 wherein portions of said base member defining said cavity are laminates formed of layers of said polymeric material and sheets of a rigid material, said laminates being substantially integral with said base member.
 7. An amphibious structure according to claim 1 wherein a portion of said base member adjacent said cavity forms a walking surface, said portion being a layer of said polymeric material integral with said base member and having a density higher than that of the remainder of said base member thereby to provide said walking surface.
 8. An amphibious structure according to claim 1 wherein each of said members have discrete integral regions of higher density than that of the remainder of said members, respectively, thereby to form structural supports of higher strength.
 9. An amphibious structure according to claim 8 wherein said closure portion has a wall portion of reduced thickness, thereby to form a translucent region therein for the admission of light.
 10. An amphibious structure comprising: mating base and closure members, each integrally formed of a polymeric material such as polyurethane, said members being secured together to define a cavity, the polymeric material of said base member having a higher density than that of said closure member, said members being sealed together with said polymeric material, whereby the coefficient of expansion of substantially all portions of said structure is substantially the same, thereby to reduce structural faults caused by temperature change, said members each having opposed mating, partitionlike protuberances integrally formed therewith, thereby to define at least partially partitioned regions within said cavity, said members together defining an orifice in said structure for ingress and egress to said cavity, and a portion of said base member adjacent said cavity having a walking surface, said portion being a layer of said polymeric material integral with said base member and having a density higher than that of the remainder of said base member, thereby to provide said walking surface. 